Patterned Retarder Fabrication via Dual Polarized UV Irradiation
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Solution Overview
Problem
The fabrication process of patterned retarders for three-dimensional image display devices is complex and costly, involving multiple steps such as coating, drying, UV curing, and baking, which increases production expenses.
Innovation Solution
A method of fabricating a patterned retarder that involves forming a retarder material layer on a substrate, irradiating first and second polarized UV rays with different polarization axes and energy densities, and baking the layer to create alternating oriented patterns with anisotropic properties, thereby simplifying the process and reducing costs by omitting the use of an orientation film and UV curing steps for the liquid crystal layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a light orientation film is formed by coating and curing a polymeric material, then the patterned retarder can be fabricated, but the fabrication process becomes complex and costly
Solution Approach 1:
The patent extracts and eliminates the light orientation film from the fabrication process. Instead of forming a separate orientation film layer through coating and UV curing, the invention directly forms the patterned retarder layer with the desired orientation properties, removing the unnecessary intermediate step and reducing process complexity
Solution Approach 2:
The patent merges the orientation film formation step with the patterned retarder formation step. By combining these two separate processes into one, the invention reduces the number of fabrication steps while achieving both the orientation pattern and the retarder functionality simultaneously
2Manufacturing precision
If multiple UV irradiation steps are performed to form oriented regions, then the patterned retarder achieves proper orientation, but the fabrication time and cost increase
Solution Approach 1:
The patent applies preliminary action by pre-aligning the polymer chains in the retarder material layer before UV irradiation. The material is prepared in an orientation state that will be fixed upon single UV irradiation, eliminating the need for multiple sequential irradiation steps to achieve the desired pattern
Solution Approach 2:
The patent skips intermediate processing steps by using a single UV irradiation step that directly forms the complete orientation pattern. Instead of performing multiple irradiation cycles with intermediate handling, the invention rushes through the process with one definitive irradiation step that achieves the desired result
3Ease of manufacture
If an orientation film is used, then the retarder material can be properly oriented, but additional materials and processing steps are required
Solution Approach 1:
The patent makes the patterned retarder layer serve multiple functions simultaneously. It acts as both the orientation-defining layer and the functional retarder layer, eliminating the need for a separate light orientation film. This multi-functionality reduces the number of layers while maintaining the ability to properly orient the retarder material
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the fabrication process and reduces costs by eliminating the need for an orientation film and UV curing steps, while maintaining the anisotropic properties necessary for effective three-dimensional image display.
Implementation Method 1
irradiating a first polarized UV ray onto the retarder material layer, the first polarized UV ray having a first polarization axis; irradiating a second polarized UV ray onto the retarder material layer, the second polarized UV ray having a second polarization axis perpendicular to the first polarization axis
Implementation Method 2
baking the retarder material layer to form first and second oriented patterns alternating with each other, each of the first and second oriented patterns having an anisotropic property
Data Source
AI summary
A method of fabricating a patterned retarder includes: forming a retarder material layer on a substrate by coating a retarder material; irradiating a first polarized UV ray onto the retarder material layer, the first polarized UV ray having a first polarization axis; irradiating a second polarized UV ray onto the retarder material layer, the second polarized UV ray having a second polarization axis perpendicular to the first polarization axis; and baking the retarder material layer to form first and second oriented patterns alternating with each other, each of the first and second oriented patterns having an anisotropic property.